Polymer composition having high flow property

ABSTRACT

A polymer composition having a high flow property is obtained by incorporating 1 to 200 parts by weight of a filler and up to 200 parts by weight of a process oil into 100 parts by weight of a polymer component consisting of at least one polybutadiene having a 1,2-addition unit content of 70 percent or higher, a crystallinity of 5 to 50 percent, and an intrinsic viscosity ( Eta ) (as measured in toluene at 30* C.) of 0.7 dl/g or higher, or a polymer component consisting of a major amount of at least one said polybutadiene and a minor amount of a rubbery polymer co-vulcanizable therewith.

Unite State's 1i atent 1 1 Ishikawa et al. Dec. 3, 1974 [-54] POLYMER COMPOSITION HAVING HIGH 3,498,963 3/1970 Ichikawa et al.... 260/93.7 FLOW PROPERTY 3,535,303 10/1970 Ichikawa et al 260/943 [75] lnventorst' Narimasa lshikawa, Tokyo; Susumu 2 Suzuki; Yasuhim ouguav bmh 9 Primary klraminerAllan Lieberman Ymmhamai K0020 Ara. Ymikmchh Assistant E.\un1im'rH. H. Fletcher all of Japan Attorney, Agent, or FirmLadas, Parry, Von Gehr. [73] Assignee: Japan Synthetic Rubber Co., Ltd., Goldsmith & Deschamps Tokyo, Japan [22] Filed: Dec. 11, 1973 21 Appl. NO.Z 423,827 1571 ABSTRACT A polymer composition having a high flow property is [30] Apphcauon Pnonty Data obtained by incorporating l to 200 parts by weight of Dec. 14, 1972 Japan 47-125532 a filler and up to 200 parts by weight of a process oil into 100 parts by weight of a polymer component con- [52] U.S. Cl. 260/5, 260/33.6 AQ, 260/42.32, sisting of at least one polybutadiene having a'l,2-

260/42.33, 260/4239, 260/80.7, 260/83.7, addition unit content of 70 percent or higher, a crys- 260/942 M, 260/94.3, 260/887, tallinity of 5 to 50 percent, and an intrinsic viscosity 260/889, 260/894 [17] (as measured in toluene at 30C.) of 0.7 dl/g or [51] Int. Cl. C08c 9/04, C080 1 1/22, C08d 9/04 higher, or a polymer component consisting of a major [58] Field of Search 260/94.2 M, 94.3, 5, 33, amount of at least one said polybutadiene and a minor 260/6 AQ, 42.32, 42.33, 42.39, 80.7, 83.7 amount of a rubbery polymer co-vulcanizable there with. [56] References Cited UNITED STATES PATENTS 13 Claims, N0 Drawings 3,457,250 7/l969 Gaeth 260/94.3

' unit POLYMER COMPOSITION HAVING HIGH FLOW PROPERTY DESCRIPTION This invention relates to a polymer composition having a high flow property comprising a high molecular weight polybutadiene having a high 1,2-addition unit content and a moderate crystallinity.

As for the polybutadiene having a high l,2-addition content (hereinafter referred to as 1,2- polybutadiene), that of a low molecular weight liquid type is currently available on the market and in use for a coating composition, etc., and concerning that of a high molecular weight type, there have only been found a few patents on an amorphous or a highly crystalline species. The amorphous 1,2-polybutadieneis rubbery in nature, and is inferior in processability, and the physical properties of both unvulcanized and vulcanized stocks are also inferior. Therefore, there is a problem in its practical use as a solid rubbery substance. On the other hand, the highly crystalline l,2-polybutadiene is a powder having a high melting point, and hence, very difficult to process, so that it has been impossible to be put in practical use.

U5. Pat. Nos. 3,498,963 and 3,522,332 disclose methods for producing high molecular weight 1,2- polybutadienes having moderate crystallinity. The present inventors have done research on physical properties of suchl ,2-polybutadienes to find that these 1,2- polybutadienes have properties intermediate between a rubber and a resin, and hence, the physical properties thereof are so characteristic that, for example, (1) the green strength is high, (2) the processability on roll is good, (3.) the mill shrinkage is very small, (4) the physical properties of vulcanizate (tensile strength, hardness, etc.) are excellent, and (5) the temperaturedependency of the flow property is high.

The present inventors have found that when such a 1,2-polybutadiene having the aforesaid characteristic properties, alone or in combination with a covulcanizable rubbery polymer, is incorporated with various compounding ingredients, there is obtained a polymer composition having such an excellent flow property that has never been found in conventional rubber compositions or resin compositions, and, in addition, capable of producing a vulcanizate with excellent physical properties.

Based on this finding the present invention has been accomplished.

According to this invention, there is provided a polymer composition having a high flow property which comprises 100 parts by weight of a polymer component consisting of at least one polybutadiene having a 1,2- addition unit content of 70 percent or higher, a crystallinity of 5 to 50 percent, and an intrinsic viscosity [1 (as measured'in toluene at C.) of 0.7 dl/g or higher, or a polymer component consisting of a major amount of at least one said polybutadiene and a minor amount of a rubbery polymer co-vulcanizable therewith; 1 to 200 parts by weight of filler; and up to 200 parts by weight ofa process oil.

The 1,2-polybutadiene to be used as the essential constituent of the polymer component in this invention is that having a l,2-addition unit content of 70 percent or higher, preferably 85 percent or higher. If the 1,2- addition unit content is below 70 percent, theaforesaid characteristic properties are lost. On the other hand,

the crystallinity should be within the range of 5 to 50 percent, preferably 10 to 30 percent, in view of the ease of mixing. If the crystallinity exceeds 50 percent, the physical properties of the vulcanizate become inferior, while if it is below 5 percent, the flow property or green strength, or the physical properties of vulcanizate are deteriorated. The intrinsic viscosity, [171 0 is 0.7 dl/g or higher, particularly preferably 1.0 dl/g or higher. When the intrinsic viscosity is lower than 0.7 dl/g, the compound tands to stick and there is obtained no composition having excellent green strength and capable of giving a vulcanizate having excellent physical properties. Further, said compound is liquid and hence is difficult to handle. Such 1,2- polybutadienes in this invention can be used alone or in combination of two or more.

The rubbery polymers co-vulcanizable with the aforesaid polybutadiene, which are used in this invention in admixture with the latter, include, for example, styrene-butadiene copolymer rubber, polybutadiene rubber, polyisoprene rubber, ethylene-propylene copolymer rubber, ethylene-propylene-diene terpolymer rubber, and natural rubber. Beside these, it is also possible to use those 1,2-polybutadienes which are amorphous or which have a crystallinity of less than 5 percent. These rubbery polymers may be used alone or in admixture of two. or more. The amount of the rubbery polymer is preferably at least 1 percent by weight but less than '50 percent by weight, particularly preferably 5 to 40 percent by weight, based on the weight of the polymer component.

By use of these rubbery polymers in combination with a major amount of the l,2-polybutadiene, the resulting polymer compositions acquire an excellent flow property and, moreover, produce a vulcanizate excellent in physical characteristics, particularly resilience compression set, tension set, flex cracking, etc.

The proportion of 1 ,2-polybutadiene in the aforesaid polymer component in this invention should exceed 50 percent by weight based on the total weight of the polymer components. If the proportion is not more than 50 percent by weight, the resulting composition can no longer be distinguishable with respect to the flow property.

The fillers for use in this invention are those which are generally used as fillers in the rubber technique. Fillers are broadly classified into two groups according to the purpose of their uses. One of the two groups includes those fillers which are used chiefly to improve practically significant physical properties, particularly abrasion resistance and hardness.,To this group belong carbon black and finely powdered anhydrous silica, which have various particle diameters and surface structures.

The other group is chiefly used as an extender and a processabilitydmproving agent, and include calcium carbonate, calcium silicate, calcium carbonate surfacecoated with a fatty'a'cid or resin acid, magnesium carbonate, magnesium oxide, titanium oxide, zinc oxide, clay, alumina, talc, etc.

The fillers in actual use are properly selected from the two groups by taking into consideration the object of its use and the cost, and may be used alone or in combination.

The amount of the filler to be used is l to 200 parts, preferably 10 to parts, by weight per 100 parts by weight of the polymer component. When used in an amount of less than 1 part by weight, the filler has no practical effect, and whenthe amount exceeds 200 parts by weight, problems arise with respect to physical properties, particularly abrasion and tensile characteristics, of the vulcanizate. I I As the process oil for use in this invention, there may be used those which are commonly used as a compounding ingredient for rubber, and the amount to be used is up to 200 parts by weight per 100 parts by weight of the polymer component.

The method of mixing the l 2-polyb utadiene used iii this invention with the rubbery polymer covulcanizable therewith has no particular restriction, and for example, solutions of both polymers may be mixed and the solvent may then be removed, or alternatively, both polymers in the form of solid may be mechanically mixed by meansof, for example, an open roll, Banbury mixer, internal mixer, kneader-blender, to obtain a sim ilar result.

Also, the method of incorporating the tiller and pro cess oil used in this invention into the polymer component has no particular restriction. For example, both ingredients may be mixed together with the polymer component by use of a usual mechanical mixing technique; either of the two ingredients mayfirst be mixed with the polymer component and then with the remaining ingredient; and where the polymer. component is 'a mixture of the l,2-.polybutadiene and the co-vulcanizable rubbery polymer, both the filler and the process oil may be mixed with 1,2-polybutadiene and then blended with the rubbery polymer, or alternatively, both ingredients may first be mixed with the rubbery polymer and then blended with the 1,2-polybutadiene.

' The polymer composition of this invention can be cured by conventional press curing, autoclave curing, and other commonly used curing procedures. Moreover, owing to the high flow property, the composition is susceptible to injection molding, which is characteristic of this invention.

"In effecting "vuaaai'zatiss', ihernayse assesses vulcani'zing agents, vulcanization accelerators, and vulcanization activators as are generally used in rubber processing, and organic peroxides may also be used.

It is, endorse, possible to incorporate "Sues commonly used compounding ingredients as antioxidants,

ultraviolet absorbers,- blowing agents, odoronts, pigments, and softening agents into the polymer composition of this invention.

'7 Owing to a high flow property, the polymer composition obtained according to this invention is very easily processable, and its vulcanizate possesses excellent physical properties, so that the polymer composition can, be used in a far broader'field than conventional general-purpose rubber compositions or resin compositions, and, furthermore, reduction in manufacturing cost is expectable by use of a large amount of filler and process oil. These advantages are of great industrial value.

' d z density of the crystalline region,-

d density of the amorphous region,

X: crystallinity in percent. 5

The value of d used was that of the crystalline 1,2- polybutadiene calculated by Natta from X-ray experi ments to be 0.963 [G. Natta, J. Polymer Sci., 20, 251 1956)]. The value of d used was 0.892 or the density of the 1,2-polybutadiene obtained by the synthesizing process proposed in US. Pat. No. 3,498,963 and found to be completely amorphous by X-ray analysis.

In the following Examples, all parts are by weight, un-

less otherwise indicated.

EXAMPLE 1 1 using th e three types of l,2-polybutadienes, the polybutadiene rubber, and the styrene-butadiene copolymer rubber, shown in Table 1, compounds were prepared by means of a Banbury mixer according to the recipes shown in Table 2.

rant 1 I Microstructural Crystalh- Intrinsic composition (76) nity' viscosity [1;] toluene Cis- Trans- 1,2

l,4 1,4 (dl/g) l,2-Polybutadiene 7.3 0 92.2 25 1.43 do.@' 10.2 o 89.8 15 L82 do. 13.3 o 86.7 0. 2.05 Polybutadiene 95.4 2.6 2.0 O 2.94

rubber Styrene butadiene 12.4 69.2 18.4 0 2.19 copolymer rubber Table 2 Sam le N0. Compounding 1 2 3 4 5 ingredient Sulfur 1.75 vulcanization accelerator MSA (N-oxydiethylene-Z-benzothiazole 0.8 0.8 0.8

sulfenamide) (part) vulcanization accelerator CZ (N- cyclohexy12-benzothiuzyl 0.8 0.8

sulfenamide) (part) Remarks Example Comparative Example The compounds thus obtained were subjected to By using the three types of 1,2-plybutadienes shown measurement of flow property andgreen strength, and Table 4 and an ethylene'propylene copolymer the ulcanizates obtained by vulcanizing the com 2 having a Propylene Content 52 percent by A ds at v for 40 weight, compounds were prepared by means of an open 9 f l 7 roll according to the recipes shown in Table 5, and sub;- measufemem 'p y p p l s- 'f jected to measurement of flow property. The results tained are shown in Table 3. obtained are shown in Table 6.

Table 3 Sample No. Item of test 1 2 3 4 Flow property (1) (Koka type flow tester) Ejected volume. Q X 10 (em /sec.) C. 0.5 2.0 2.7 3.3 1.5 C. 2.7 4.8 2.2 4.0 3.1 C. 16.0 1 0 2.2 4.8 4.5 Green strength At room temperature Tensile strength (kglem 97.0 80.8 4.6 1.4 3.8 v

Elongation 550 640 310 2000 420 At 40C.

Tensile strength (kg/cm) 78.7 59.4 2.7 r 1.2 2.4'

Elongation (92:) 540 630 260 340. 290 At 80C. v

Tensile strength (kg/cm) 11.9 3.4 1.3 0.9 0.9

Elongation 440 220 270 320 310 Physical properties of vuleanizate 300% Modulus I (kg/cm*) 4 121 99 86 73 91 Tensile strength (kg/cm) 162 182 151 179 268 Elongation (70) 670 750 480 530 590 Hardness (.llS H5) 91 86 63 58 62 Remarks Example Comparative Example Note: (1) Measured under a load of 50 kg Nozzle: 1 mm d X 2 mm EXAMPLE 2 Table 4 1,2-addition Crystaunit contcut llinity {1 toluene 1.2-Polybutadiene 92.3 24 1.39

do. v 90.0 17 1.58

Note: (I Measured under a load of 30 kg. Nozzle: l mm in X I mm The compounds of Sample Nos. 6, 7 and 8 were further mixed with the vulcanizing ingredients, shown in Table 7, by means of a roll mill, then press-cured at 160C. for 15 minutes, and the resulting vulcanizates were subjected to mesurement of physical properties. The results obtained are shown in Table 7.

Table 7 Sample No. 3

Compoundl(6) il(7) 12(8) ing ingredient and item of test Vul'canizing ingredients (part) Diethylene glycol 2 vulcanization accelerator TS (tetramethylthiuram mono- 0.5

sulfide) Mixed vulcanization accelerator DM H (dibenzothiazyl disulftde l 2 hexamethylene tetramine) Sulfur l.5

Physical properties of vulcanizate IOOX' modulus (kg/cm) l0 16 56 300% modulus (kg/cm) 42 88 Tensile strength (kg/cm) 28 6| l80 Elongation ('1'), 260 380 520 Hardness (.llS Hs) Si 60 90 Tear strength (kg/cm) l7 21; 70 Resilience (7H 60 56 36 Remarks Comparative Exam- Example ple The compounds of Sample Nos. 8 and 9 we re each mixed with 3 parts of di-tert-butylperoxy-3,3,6-trirnethylcyclohexane, and the resulting mixtures were press- Compound- Table 5 Table 8 Sam le bio. 6' 7 s 9 Sam le cowpwmlmg item of test 13(8) 14 9 ingredient Physical properties l,2-Poiybutadiene(part) I00 60 100% d l k 95 55 300% modulus (kg/cm gvi r Tensile strength (kg/cm) 133 60 (pan) 1 60 Elongation 180 I 140 Ethylene-propylene copolymer Hardness (JlS) Hs) 92 35 rubber (part) 0 Tear strength (kg/cm) 52 30 Zinc carbonate (part) 2 Resilience 33 36 Stearic acid (part) I Tension set 23 15 White carbon (hydrated silica) Remarks Examples (part) 1 Remarks Comparative Example Example EXAMPLE 3 T 6 liy using 1,2-polybutadiene @having a 1,2-addition unit content of 91.5 percent, a crystallinity of percent, and an intrinsic viscosity, ['rfl of 1.39 Sample No. "em or test 7 6 7 8 9 20 dl/g and the styrene-butadiene copolymer rubber used in Example 1, compounds were prepared by means of Flow P p y (Kaka W an open roll according to the compounding recipes shown in Table 9 and the v lca t bt d b Ejected volume, O X l0 u es 0 y (cm/sec.) l20 C'. 0.8 L3 8.5 5.0 vuncamzmg the compounds at 160 C. for 15 minutes 25 were subjected to measurement of various physical Remarks Comparative Example Example properties. The results obtained are shown in Table 9.

Table 9 Sample No.

ing ingredient and item of test l,2-Polybutadiene(part) so 10 so Styrenebutadiene copolymer rubber (part) 0 Compounding ingredient (part) Zinc carbonate 2 Stearic acid 1 White carbon (hydrated silica) Diethylene glycol 2 Vulcanization accelerator (kg/cm) (kg/cm") (kg/cm) (JiS Hs) (kg/cm) 50,000 times 100,000 times Remarks (UCut growth 2 mm What is claimed is:

l. A polymer composition having a high flow property, which compriseslOO parts by weight of a polymer component consisting of at least one polybutadiene having a 1,2-addition unit contentof 70 percent or higher, a crystallinity of 5 to 50 percent, and an intrinsic viscosity of 0.7 dl/g or higher as measured in toluene at 30C., or a polymer component consisting of a major amount of at least one said polybutadiene and a minor amount of a rubbery polymer co-vulcanizable therewith; 1 to 200 parts by weight of a filler; and up to 200 parts by weight of a process oil. v

2. A polymer composition according to claim 1, wherein the polybutadiene has a 1,2-addition unit content of 85 percent or higher.

3. A polymer composition according to claim 1, wherein the polybutadiene has a crystallinity of 10 to 30 percent.

4. A polymer composition according to claim 1, wherein the polybutadiene has an intrinsic viscosity of 1.0 dl/g or higher as measured in toluene at 30C.

5. A polymer composition according to claim 1,

wherein the polybutadiene has a l,2-addition unit content of 85 percent or higher, a crystallinity of 10 to 30 percent and an intrinsic viscosity of 1.0 dl/g or higher as measured in toluene at 30C.

6. A polymer composition according to claim 1, wherein the polymer component consists of at least one polybutadiene having a 1,2-addition unit content of 70 percent or higher, a crystallinityof 5 to 50 percent and an intrinsic viscosity of 0.7 dl/g or higher as measured in toluene at 30C.

7. A polymer composition according to claim 1, wherein the rubbery polymer is selected from the group consisting of styrene-butadiene copolymer rubbers,

10 polybutadiene rubbers, polyisoprene rubbers, ethylene.- propylene copolymer rubbers, ethylene-propylenediene terpolymer rubbers, amorphous 1,2-

polybutadiene or 1,2-polybutadiene having a crystallin- 11. A polymer composition according to claim 1,

wherein the tiller is selected from the group consisting of calcium carbonate, calcium silicate, magnesium carbonate, magnesium oxide, titanium oxide, zinc oxide, clay, alumina, talc, and calcium carbonate surfacecated with a fatty acid or resin acid. v

12. A polymer composition according to claim 1,

wherein the amount of the filler is 10 to 100 parts by weight. i v

13. A vulcanized product of the composition according to claim 1. 

1. A POLYMER COMPOSITION HAVING A HIGH FLOW PROPERTY, WHICH COMPRISES 100 PARTS BY WEIGHT OF A POLYMER COMPONENT CONSISTING OF AT LEAST ONE POLUBUTADIENE HAVING A 1,2-ADDITION UNIT CONTENT OF 70 PERCENT O HIGHER, A CRYSTALLINITY OF 5 TO 50 PERCENT, AND AN INTRINSIC VISCOSITY OF 0.7 DL/G OR HIGHER AS MEASURED, IN TOLUENE AT 30:C OR A POLYMER COMPONENT CONSISTING OF A MAJOR AMOUNT OF AT LEAST ONE SAID POLYBUTADIENE AND A MINOR AMOUNT OF A RUBBERY POLYMER CO-VULCANIZABLE THEREWITH; 1 TO 200 PARTS BY WEIGHT OF A FILLER; AND UP TO 200 PARTS BY WEIGHT OF A PROCESS OIL.
 2. A polymer composition according to claim 1, wherein the polybutadiene has a 1,2-addition unit content of 85 percent or higher.
 3. A polymer composition according to claim 1, wherein the polybutadiene has a crystallinity of 10 to 30 percent.
 4. A polymer composition according to claim 1, wherein the polybutadiene has an intrinsic viscosity of 1.0 dl/g or higher as measured in toluene at 30*C.
 5. A polymer composition according to claim 1, wherein the polybutadiene has a 1,2-addition unit content of 85 percent or higher, a crystallinity of 10 to 30 percent and an intrinsIc viscosity of 1.0 dl/g or higher as measured in toluene at 30*C.
 6. A polymer composition according to claim 1, wherein the polymer component consists of at least one polybutadiene having a 1,2-addition unit content of 70 percent or higher, a crystallinity of 5 to 50 percent and an intrinsic viscosity of 0.7 dl/g or higher as measured in toluene at 30*C.
 7. A polymer composition according to claim 1, wherein the rubbery polymer is selected from the group consisting of styrene-butadiene copolymer rubbers, polybutadiene rubbers, polyisoprene rubbers, ethylene-propylene copolymer rubbers, ethylene-propylene-diene terpolymer rubbers, amorphous 1,2-polybutadiene or 1,2-polybutadiene having a crystallinity of less than 5 percent, and natural rubber.
 8. A polymer composition according to claim 1, wherein the polymer component contains at least 1 percent by weight but less than 50 percent by weight of the rubbery polymer.
 9. A polymer composition according to claim 8, wherein the amount of the rubbery polymer is 5 to 40 percent by weight based on the weight of the polymer component.
 10. A polymer composition according to claim 1, wherein the filler is carbon black or finely powdered anhydrous silica.
 11. A polymer composition according to claim 1, wherein the filler is selected from the group consisting of calcium carbonate, calcium silicate, magnesium carbonate, magnesium oxide, titanium oxide, zinc oxide, clay, alumina, talc, and calcium carbonate surface-cated with a fatty acid or resin acid.
 12. A polymer composition according to claim 1, wherein the amount of the filler is 10 to 100 parts by weight.
 13. A vulcanized product of the composition according to claim 